SPEEDRIVE INSTRUCTIONS MANUAL

Transcription

1 EN SPEEDRIVE INSTRUCTIONS MANUAL

2 Safety warning. The following symbols shown beside a paragraph represent danger warnings associated to the failure to comply with the corresponding instructions. DANGER! Risk of electrocution. DANGER! Not observing this precaution involves a risk of electrocution. Warns that not observing the precaution involves a risk of damage to people and/or materials. WARNING Warns that not observing the precaution involves a risk of damage to the pump or the installation. TABLE OF CONTENTS 1) GENERAL INFORMATION...3 2) TECHNICAL SPECIFICATIONS ) Models ) Dimensions ) Features ) INSTALLATION ) Hydraulic installation ) Electrical connection to the motor ) Installation on the pump ) Power supply connection ) Signals wires connection ) OPERATING MODES ) SETUP ) Definitions ) Browsing ) Description of the menus ) PROTECTION AND ERRORS ELECTRONIC CIRCUIT FAILURE ) MULTIPLE OPERATION ) Booster set with "On-Off" auxiliary pumps ) Booster set with inverter regulated auxiliary pumps ) MAIN COMPONENTS ) EVIDENCE OF CONFORMITY ) LOW VOLTAGE ) ELECTROMAGNETIC COMPATIBILITY ) OTHER INSTALLATIONS ) MENU DIAGRAM

3 1) GENERAL INFORMATION. The Speedrive inverters have been designed to adjust the speed of three-phase motors used with water pumps. The inverter receives a signal from the pressure transducer that is proportional to the installation's pressure. This signal is processed and it regulates the speed of the motor to keep the pressure constant, even though the consumption of water varies. It can be used with 50Hz or 60Hz motors. Selecting the output frequency with the menu option. The units have a constant pressure control system. The PI system used provides two numerical constants that are processed by the unit to achieve a stable regulation. This type of regulation can greatly reduce the consumption of energy when compared to unregulated systems, since the consumption of electricity will be proportional to the consumption of water. Another of the advantages of regulated units is the decrease in voltage surges, softening current peaks and, therefore, increasing the working life of the pump. WARNING: Correct compliance with the installation and operating instructions and the electrical connection diagrams will guarantee the correct operation of the unit. DANGER: The failure to follow the instructions in this Manual can lead to motor overloads, diminishment in technical characteristics, reduction of the unit's working life and all types of subsequent results, for which we decline any responsibility. 2) TECHNICAL SPECIFICATIONS. 2.1) Models. Model Speedrive M2 2.2) Dimensions. Power supply voltage [V] 1~ 230V AC ±10% INPUT OUTPUT Dimensions Weight Max. Recommended Max. Motor rated line motor voltage A B current protection current [A] [A] [A] [V] [mm] [mm] [kg] ~ 230V AC T2 3~ 400V AC ~ 400V T3 ±10% AC ) Features. Degree of protection: IP55. Maximum working ambient temperature: 40 ºC. Inputs: 1 analogue 4-20mA, with 24V DC power supply. 1 digital input for the level switch. Outputs: Only M..., 1 potential-free contact, maximum current 2A at 250V AC. Communications: RS 485 serial port

4 3) INSTALLATION. 3.1) Hydraulic installation ) Installation layout. 1. Pump with Speedrive Non-return valve. Not required others non-return valves in the delivery pipe. 3. Pressure transducer. The 4-20 ma, 10 bar type, EMC according EN Accumulator. Its sole function is to compensate minor water losses in the installation, preventing continuous pump start-ups and stops. The accumulator's volume must be at least 10% of the nominal flow of the pump(s) installed, calculated in litres per minute. (For ex.: Multi35 5, QMAX=100 [l/min]x0.1=10 accumulator 10l) The preload pressure must be 1 bar below to the rated pressure ) Hydraulic connections. See the pump manual. For facilities in negative suction, it is required that the pipes are primed completely. 3.2) Electrical connection to the motor ) Speedrive with single-phase input (Figure 1): The motor must be connected to a 230 V power supply source. The cable (1) supplied with the inverter must be connected to the motor. If you wish to activate the 60Hz motor output, select the corresponding parameter in the menu. Make sure that electrical consumption shown on the motor's data plate does not exceed that supplied by the inverter. DANGER. Risk of electrocution. Always connect the supplied grounding cable (2) between the motor and inverter set. DANGER. Risk of electrocution. Never open the Speedrive cover before disconnecting the power supply during at least 5 minutes. Yellow/Green Black Brown Blue Figure 1-4 -

5 3.2.2) Speedrive with three-phase input (Figure 2): The motor must be connected to a 400 V power supply source. The cable (1) supplied with the frequency inverter must be connected to the motor. If you wish to activate the 60Hz motor output, select the corresponding parameter in the menu. Make sure that electrical consumption shown on the motor's data plate does not exceed that supplied by the inverter. DANGER. Risk of electrocution. Always connect the supplied grounding cable (2) between the motor and inverter set. DANGER. Risk of electrocution. Never open the Speedrive cover before disconnecting the power supply during at least 5 minutes. Yellow/Green Negro Marrón Azul Black Brown Blue Figure 2 3.3) Installation on the pump. The Speedrive is installed on the motor with a special supplied adapter. The inverter is cooled with the use of the motor's cooling elements. The unit has been designed for vertical and horizontal installation ) Motor adapter (Figure 3): Replace the connections box with the supplied motor adapter. Use the same screws. Torque 1~1.2 Nm. Figure 3-5 -

6 3.3.2) Speedrive. e. Installation of the Speedrive on the adapter. Use the screws (1) supplied. Torque: 3 Nm. Single-Phase Version Three-Phase Version 1 1 Prepare the motor wires with ferrites: connect the grounding wire (2) Connect the motor wires to the provided socket (3) Single-Phase Version Three-Phase Version Figure 4 Figure 5-6 -

7 3.4) Power supply connection. DANGER. Risk of electrocution. Connection and grounding are compulsory. All electrical connections will be in accordance with the IEC Regulations (electrical installation in buildings) or the regulations in force in the destination country and local regulations. The power supply line of equipment must be adequately protected. These protection elements will prevent damage to persons during an electrical leakage. An exclusive power supply line is recommended. The system protection will be based on an earth leakage switch (I n = 30 ma). The recommended earth leakage switch is "class A" for pulsed and continuous currents, marked with the following symbols: The earth leakage value will depend on the number of units connected to the line and their power. Motor size Leakage current 0.75 to 3 kw < 3.5 ma 4 to 5.5 kw < 5 ma The electrical installation should have a multiple separation system with contact openings 3 mm. Single-phase frequency inverters. These units are supplied with a H07 RN-F power supply cable, 2m length and a connection plug. The power supply input must be single-phase, at 230 V, 50 or 60 Hz. See Figure 6 for reference. Voltage variations allowed ±10 Three-phase frequency inverters. These units have a three-phase power supply input, at 400 V, 50 or 60 Hz. The cabling procedures must be undertaken by a professional installation entity. Connection socket according figure 5 (4). Connections, in accordance with Figure 7. 7 Voltage variations allowed ±10%. Preparing the power supply wires: - 7 -

8 3.5) Signals wires connection. Single-phase version Three-Phase Version Figure 6 Figure RS 485 communications output to connect various inverters. Up to 4 units. 2.- Auxiliary input for an external level switch or a potential-free contact to activate or stop the circuit. Note: This input is supplied from the factory with an electric cable bridge. 3.- Input of the 4-20mA pressure transducer. 4.- Potential-free auxiliary input. Not used. 5.- Auxiliary transducer input. Not used. 6.- Only in single-phase versions. 230 V potential output, 2A maximum, external display or acoustic operation for alarm signals. 7.- Micro-switches used to configure the inverter's operation. WARNING: All external cabling connections must use terminal tips on the ends of each cable. External cables must comply with the corresponding electrical safety and insulation regulations. Installation should be made by qualified service personnel. Avoid any cable pieces from falling inside the circuit, which could lead to its destruction. DANGER. Risk of electrocution. If the unit has to be uncovered due to any circumstance, first disconnect the power supply and wait 5 minutes before starting work with the circuit. The circuit's capacitors store energy. There is enough energy inside the circuit to cause a strong electric discharge, even when the unit is not powered

9 If necessary, reconnect the display cable to the motherboard. Give special attention to positioning. Single-Phase Version Three-Phase Version 4) OPERATING MODES. Automatic mode. This is the common operating mode. The inverter controls the motor's rotation speed to maintain a constant pressure in the installation (set pressure). Manual mode. Allows the pump start-up or stop manually at an adjustable frequency. 5) SETUP. Espa ESD pumps and Espa pressure booster sets are pre-configured in origin with an optimum pressure set point for equipped pumps. Do not need any further adjustment. Speedrive module purchased separately, is necessary its configuration, according to the following paragraphs. 5.1) Definitions. Set pressure: is the pressure that the unit will maintain in the installation. Differential l pressure: is the differential pressure required for the unit to activate again. Stop frequency: frequency at which the inverter stops the pump. Stop delay: timer used by the unit before it stops. Auxiliary on-off off pump: auxiliary pump that is not equipped with Speedrive. Auxiliary regulated pump: auxiliary pump that is equipped with a Speedrive. 5.2) Browsing. Screen displaying the menus Failure See description on screen Flashing = pump waiting Fixed = pump operating Power supply plug-in Browsing keys Browsing the menus. Variation of the flashing parameter. Browsing a submenu

10 Accepting changes. Return to the general screen from display of parameters. Pressure: View 2.0bar Menu Backlight The screen is backlit display for better reading. To save power, the backlight turns off in 60 seconds without pressing any keys. To activate the backlight, press OK. Without backlight does not work any other key. 5.3) Description of the menus. START SCREENS Introduction screen Displayed during a few seconds when connecting the equipment. Indicates: model, software version and pressure sensor configuration. MAIN SCREEN Start screen The pump is not activated. To start the pump manually, press (Man) For automatic operation, press (Auto) To configure parameters, press (Config) It shows the system pressure. The pump will run automatically, as needed. To display parameters, press (View) To return to the start screen, press (Menu) MANUAL OPERATION It shows the system pressure and Speedrive output frequency. Press ON, to activate the pump. Start-up is always performed at 15Hz. Press OFF, to stop the pump. Press or, to adjust the frequency. Press OK to exit the screen. CONFIGURATION Screen descriptions: - Top : parameter being configured. - Lower left : current value of the parameter. - Lower right, "flashing": new value being configured. Press OK to confirm. LANGUAGE Select the desired language. MOTOR FREQUENCY Configuration of the nominal frequency of the motor, 50Hz or 60Hz. Check the motor's nameplate. Note: This screen only appears in the initial preset or retrieving the factory settings. MAXIMUM PUMP HEIGHT Setting the maximum pressure the pump can provide. Check the pump s nameplate. Note: This screen only appears in the initial preset or retrieving the factory settings

11 MAXIMUM MOTOR CURRENT Maximum operating current of the motor. Adjust in accordance with the motor's data plate, plus 10%. Note: This screen only appears in the initial preset or retrieving the factory settings NOMINAL PRESSURE Configuration of the work pressure of the unit. CONFIGURATION OF THE STOP FREQUENCY ADDITIONAL PARAMETERS SETTING CALCULATED STOP FREQUENCY The stop frequency is calculated automatically. Will be recalculated every time that is changed the nominal pressure. To set a value in the manual mode, press (Man) STOP FREQUENCY MANUALLY Enter the desired stop frequency. Note: This value should only be entered by experts. FINE ADJUSTMENTS To set additional parameters, press (Config) To complete the setup, press (Exit) DIFFERENTIAL PRESSURE Configuration of the difference between the set and start-up pressure. For ex. : 3 bars set 0.5 bars differential = 2.5 bars start-up STOP DELAY Timing of the unit before a stop. This timing process is associated to the stop frequency. REVESE ROTATION To check the motor rotation direction, press (Check) To change rotation direction, press (Change) Starting the motor, to 25Hz, for CHECK TURN DIRECTION Press ON, to activate the pump. Press OFF, to stop the pump. Press OK to exit the screen. Confirm INVERT TURN. Change to "YES" to reverse the turn direction AUXILIARY PUMPS For adjust auxiliary pumps parameters, press (Adjust) If there are no regulated pumps, press to advance to screen

12 CONFIGURATION SUBMENU FOR AUXILIARY PUMPS MAXIMUM CURRENT OF THE AUXILIARY PUMP (ELV only) Maximum motor current of the auxiliary pumps equipped with "ELV" box. All motors have the same power rating. Adjust in accordance with the motor's data plate, plus 10%. For auxiliary pumps equipped with "SPEEDRIVE" box this parameter must be regulated individually, for each equipment. The value of this screen is ignored. FREQUENCY "ON" FOR AUXILIARY PUMPS Auxiliary pump activation frequency. Maximum frequency achieved by the main pump. At this frequency, the 1 st auxiliary pump is activated, lowering the main pump frequency until it balances the set pressure. If the main pump reaches this frequency again, the 2 nd auxiliary pump will be activated, and so forth. The number of auxiliary pumps does not have to be determined, since the circuit communications system detects its number. DELAY ON Delay time between the activation of auxiliary pumps. Avoid continuous start-ups of reserve pumps due to fluctuations in the installation. HYSTERESIS OFF Difference between the stop frequency of the main pump and each auxiliary pump. DELAY HYSTERESIS OFF Delay time in the stop sequence of auxiliary pumps. PARAMETER RESET FACTORY PARAMETER To reset all changes of parameters and return to default settings, click OK. Confirm the change to default parameters. Select "Yes" and click OK to return to the default settings. CONFIGURATION OF ADVANCED PARAMETERS AND METER RESET ADVANCED PARAMETERS To modify the advanced parameters or reset the meters, press To complete the setup, click OK. ATTENTION. These parameters can only be configured by expert staff. PASSWORD There are 2 passwords available, depending on the action: + OK: to reset all meters. + OK: to adjust the unit's regulation and operation

13 SUBMENU USED TO RESET METERS (password ) RESET METER Select "Yes" and click OK to reset all meters. Confirm RESET METER. Select "Yes" and click OK to confirm reset all meters. RESET ALARMS Select "Yes" and click OK to reset all alarms. Confirm RESET ALARMS. Select "Yes" and click OK to confirm reset all alarms. SUBMENU FOR THE CONFIGURATION OF ADVANCED PARAMETERS (password ) WORK PROPORTIONAL CONSTANT Allows the variation of the unit's proportional constant after start-up. WORK INTEGRAL CONSTANT Allows the variation of the unit's integral constant after start-up. START PROPORTIONAL CONSTANT Allows the variation of the unit's proportional constant upon start-up. STAR INTEGRAL CONSTANT Allows the variation of the unit's integral constant upon start-up. PWM FREQUENCY (Pulse Width Modulation) Allows the variation of the internal module switching tasks. A high-pitched sound will be heard from the motor (depending on the type of motor) when the switching frequency is varied. DISPLAY OF PARAMETERS DISPLAY OF PARAMETERS Press OK to confirm. Parameters can only be displayed, not modified. To display the alarms, press (Alarm) To return to the main screen, press (Auto) From any screen, tap OK to return to the main screen 2.1 NOMINAL PRESSURE Work pressure assigned to the unit

14 DIFFERENTIAL PRESSURE Difference between the set and start-up pressure. For ex. : 3 bars set 0.5 bars differential = 2.5 bars start-up MAXIMUM MOTOR CURRENT Maximum configured current/ Present current STOP FREQUENCY Stop frequency of the inverter / Present output frequency STOP DELAY Timing before a stop. MODULE TEMPERATURE Current temperature of the module or circuit. DISPLAY OF THE ALARM LOG DISPLAY ALARMS Press OK to confirm. To display the log, press (Hist) To display the parameters, press (Param) From any screen, tap OK to return to the main screen 2.1 OVERCURRENT Number of times an overcurrent is detected. (see Section 6) SHORT-CIRCUIT Number of times a fault caused by a short-circuit is detected. (see Section 6) VOLTAGE Number of times the inverter has stopped due to a voltage fault. (see Section 6) MODULE TEMPERATURE Number of times the inverter has stopped due to excess temperature in the module. (see Section 6) LACK OF WATER LEVEL IN TANK Number of times the inverter has stopped by activating the probe level. (see Section 6) DISPLAY OF THE OPERATION LOG DISPLAY LOG Press Ok to confirm. To display the alarms, press (Alarm)

15 From any screen, tap OK to return to the main screen 2.1 NUMBER OF START-UPS Number of pump start-ups. OPERATING HOURS Number of hours of operation of the pump. LINE CONNECTION Number of hours of connection to the line, even when the pump is stopped. 6) PROTECTION AND ERRORS. OVERCURRENT ERROR SHORT-CIRCUIT ERROR TEMPERATURE ERROR LACK LEVEL ERROR VOLTAGE ERROR PRESS TRANSD. ERROR OVERCURRENTS The circuit permanently controls the motor s current consumption. If the current exceeds the values established in parameter "MAXIMUM MOTOR CURRENT" at any moment, the system will stop. The reset is automatic. If the error is not solved 4 new attempts* are performed. If the error is still present after the fourth attempt, the system will be set to a permanent fault. Press OK to reset. The start screen (#2) will appear. SHORT-CIRCUIT The state of connections will be diagnosed upon the motor's start-up. The system will stop when a short-circuit is detected in the motor. The reset is automatic. If the error is not solved 4 new attempts* are performed. If the error is still present after the fourth attempt, the system will be set to a permanent fault. MODULE TEMPERATURE The module's (T models) or circuit's (M models) temperature is monitored at all times. If the limit values established (not configurable) are exceeded in each circuit, the system will stop. The reset is automatic when the normal temperature is reinstated. LACK OF WATER LEVEL IN TANK If you have installed a float level in the inlet water tank (see apt. 3.5, n º 2), the water level is below the minimum. The reset is automatic when the water level recovered. VOLTAGE The input voltage of the system will be monitored constantly. The system will stop if the ±10% limits are exceeded. The reset is automatic when the nominal voltage is reinstated. PRESSURE TRANSDUCER The pressure transducer connected to the unit is not working properly The system will stop. (For booster sets, if other transducers are connected to Speedrive slaves, the booster will not stop and automatically switch to another transducer)

16 LACK OF WATER ERROR INTERNAL FAILURE ERROR EEPROM FILURE ERROR LACK OF WATER / PIPE BREAKAGE If the unit works more than 60 seconds at 50Hz, but the pressure does not exceed 0.3 bar, is declared "error for lack of water." the system will be set to a permanent fault. Press OK to reset. ELECTRONIC CIRCUIT FAILURE The electronic circuit is breakdown. The Speedrive stops working. It can only be repaired by official technical service. MEMORY MODULE FAILURE EEPROM memory module has had a serious malfunction and has stopped working. The Speedrive enters standby mode, with a reference pressure of 2 bar. It can only be repaired by official technical service. DISPLAY CONNECTION ERROR 3 LED sequential lighting indicates an error in connection the display signal cable to the motherboard. Reverse connector. Take care to position *= Illustration of the sequence and times of the 4 attempts, if not none of them succeed: ON OFF 1º 2º 3º 4º 7) MULTIPLE OPERATION. The Speedrive inverter can control more up to 4 pumps, equipped with various Espa solutions, for a multiple pump booster set control. a) Booster set with "On-Off" auxiliary pumps, equipped with "ELV" box. b) Booster set with inverter regulated auxiliary pumps, equipped with "Speedrive" box in slave mode. Communication is through communication port RS ) Booster set with "On-Off" Off" auxiliary pumps Sequence of Operation: - Faced with a demand for water, the pump A starts fast enough to meet the need for installation. - If the need is beyond the capacity of the pump A, pump B is activated at 100% capacity. The pump A reduce speed to meet demand (exchange rate set according to menu 10.1) - If the need exceeds the capacity of the pumps A + B, the pump C is activated. The pump A reduce speed to meet demand. - And successively... The operation mode is alternated. Each activation of the booster set, the order of start pumps is random. This will equal the operation hours. Installation and connections. The Speedrive installation and electrical wiring is done as described in this manual. For installation and connections of the modules "ELV", see its installation manual. The connection of the pressure transducer must be made solely on the drive Speedrive. A 2-wire twisted and shielded cable 0.5mm2 section must make the communication between devices

17 Figure 8 Adjust the micro-switches on the ELV as needed. See section 5 of the ELV manual. Respect the polarity of the RS-485connection: A B A B A B A B Configuration. Set Speedrive menus as follows: AUXILIARY PUMP Press (Adjust) for the adjustment of the parameters that govern to the auxiliary pumps. MAXIMUM CURRENT OF THE AUXILIARY PUMP. Set the maximum motor current of the auxiliary pumps, according to his motor's data plate plus 10%. All auxiliary pump motors should be of the same power. CHANGE FREQUENCY Set the maximum frequency of the main pump to be activated the auxiliary pumps. The number of auxiliary pumps does not have to be determined, since the circuit communications system detects the number (maximum 4). DELAY ON Set the desired delay time before the start of each auxiliary pump. Programming cascade spreads auxiliary pumps. Ignore. Press Ignore. Press 7.2) Booster set with inverter regulated auxiliary pumps. Synchronous sequence of Operation: - Faced with a demand for water, the pump A starts fast enough to meet the need for installation

18 - If the need is beyond the capacity of the pump A, pump B is activated. Both pumps sync speed to meet demand (exchange rate set according to menu 10.4) - If the need exceeds the capacity of the pumps A + B, the pump C is activated. Three pumps sync speed to meet demand. - And successively... The operation mode is alternated. For each activation of the booster set, the order of start pumps is random. This will equal the operation hours. Installation and connections. The Speedrive installation and electrical wiring is done as described in this manual. The connection of the pressure transducer must be made solely on the "Master" Speedrive. A 2-wire twisted and shielded cable 0.5mm2 section must make the communication between devices. Figure 9 Adjust the micro-switches (figure 6 o figure 7) as needed: MASTER/SLAVE SWITCH 1 SWITCH 2 SWITCH 3 SWITCH 4 MASTER OFF OFF OFF OFF SLAVE 1 OFF OFF OFF ON SLAVE 2 OFF OFF ON OFF SLAVE 3 OFF OFF ON ON Respect the polarity of the RS-485connection: A B A B A B A B Configuration. Set master Speedrive menus as follows: AUXILIARY PUMP Press (Adjust) for the adjustment of the parameters that govern to the auxiliary pumps. Ignore. Press

19 CHANGE FREQUENCY Set the maximum frequency of the main pump to be activated the auxiliary pumps. The number of auxiliary pumps does not have to be determined, since the circuit communications system detects the number (maximum of 4). DELAY ON Set the desired delay time before the start of each auxiliary pump. Programming cascade spreads auxiliary pumps. HYSTERESIS OFF Set the desired difference between the stop frequency of the main pump and each auxiliary pump. Programming cascade spreads auxiliary pumps. DELAY OFF. Set the desired delay time in the stop sequence of auxiliary pumps. Programming cascade spreads auxiliary pumps. Set slave Speedrive menu as follows: MOTOR FREQUENCY Configuration of the nominal frequency of the motor, 50Hz or 60Hz. Check the motor's nameplate. Note: This screen only appears in the initial preset or retrieving the factory settings. MAXIMUM MOTOR CURRENT Maximum operating current of the motor. Adjust in accordance with the motor's data plate, plus 10%. Note: This screen only appears in the initial preset or retrieving the factory settings Transducer failure. In a booster unit equipped with multiple transducers, if the main transducer fails, it automatically switches to a secondary transducer. In this case, displays the following error: MAIN TRANSDUCER ERROR It appears an asterisk in the pressure display = it is reading the pressure of an auxiliary transducer

20 8) MAIN COMPONENTS Motor adapter with connections box 85x85 2 Motor adapter with connections box 70x70 3 Speedrive box with electronic power circuit 4 Cable with plug (only M... versions) 5 Electronic control circuit 6 Speedrive cover 9) EVIDENCE OF CONFORMITY 9.1) LOW VOLTAGE. Speedrive is in compliance with directive 2006/95/CE (low voltage) and with harmonized standards EN and EN ) ELECTROMAGNETIC COMPATIBILITY. Speedrive M1 and M2 are in compliance with directive 2004/108/CE (electromagnetic compatibility), for industrial environment. For residential environment, it will require the installation of a lead currents filter to prevent interference in the mains. The Espa filter code is recommended. Speedrive T1, T2 and T3 are in compliance with directive 2004/108/CE (electromagnetic compatibility) for industrial environment. Harmonized standards: EN and EN ) OTHER INSTALLATIONS. Speedrive module has been designed, and is certified, for united installation to the pump electric motor. Any other configuration or installation can be subject to additional certifications. ESPA 2025 SL disclaims all liability for uses not covered in this manual. Pere Tubert Technical manager ESPA 2025, S.L

21 10) MENU DIAGRAM

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24 ESPA 2025, S.L. C/ Mieres, s/n BANYOLES GIRONA SPAIN Cod.: /05